Relay PCA
P/N 04523
Addendum
to M100E, M200E and M400E
Operator Manuals
© TELEDYNE INSTRUMENTS ADVANCED POLLUTION INSTRUMENTATION
(T-API)
9480 CARROLL PARK DRIVE
SAN DIEGO, CA 92121-5201
USA
Toll-free Phone: 800-324-5190
Phone: 858-657-9800
Fax: 858-657-9816
Email: [email protected]
Website: http://www.teledyne-api.com/
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20 March 2009
Copyright 2007 T-API Inc.
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Relay PCA 04523
Addendum to E-Series Operator Manuals
SAFETY MESSAGES
For general safety information please refer to your M100E/M200E/M400E operator’s manual.
CAUTION
Never disconnect electronic circuit boards, wiring harnesses or electronic
subassemblies while the unit is under power.
Printed circuit assemblies (PCAs) are sensitive to electro-static
discharges too small to be felt by the human nervous system. Failure
to use ESD protection when working with electronic assemblies will
void the instrument warranty.
See Chapter 12 of your M100E/M200E/M400E operator’s manual for
more information on preventing ESD damage.
NOTE
Technical Assistance regarding the use and maintenance of the any Teledyne
Instruments product can be obtained by:
Contacting Teledyne Instruments’ Customer Service Department at 800-324-5190
or
Via the internet at http://www.teledyne-api.com/inquiries.asp
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TABLE OF CONTENTS
1. INTRODUCTION........................................................................................................................... 1
1.1. What’s the Same.....................................................................................................................1
1.2. What’s Different......................................................................................................................2
2.1. Power Distribution...................................................................................................................5
2.2. Valve Control..........................................................................................................................9
2.3. Status LEDs & Watch Dog Circuitry ..........................................................................................10
2.3.1. Watchdog Indicator (D1)..................................................................................................10
2.4. Heater Control Loop...............................................................................................................11
2.4.1. Thermocouple Inputs and Configuration Jumper (JP5) ..........................................................12
2.5. DC Power Supply Test Points...................................................................................................14
3. TROUBLE SHOOTING AND REPAIR..............................................................................................15
3.1. Removing / Replacing the Relay PCA from the Instrument...........................................................15
4. SCHEMATICS AND SPARE PARTS FOR RELAY PCA P/N 04523.....................................................16
LIST OF FIGURES
Relay PCA Layout (P/N04523)..........................................................................2
Power Distribution Block Diagram.....................................................................5
Pump AC Power Jumpers (JP7) ........................................................................7
LIST OF TABLES
DC Power Supply Acceptable Levels................................................................. 14
List of Included Electronic Schematics.............................................................. 16
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1. INTRODUCTION
This addendum documents a recent upgrade to the relay card installed in some of the M100E,
M200E and M400E series analyzers. Specifically, a new relay PCA design, P/N 04523 replaces P/N
03955 and all of its versions in the following instruments.
It also corrects several errors related to the function of the relay PCA.
Table 1-1:
List of Analyzers Using New Relay PCA P/N04523
RELAY PCA VERSION1
PRODUCT FAMILY
MODEL
045230100 045230200
M100E
M100EH
M101E
UV Fluorescence
M102E
M200E
M200EH
M200EM
M201E
Chemiluminescence
UV Absorption
Analyzers
M400E
1
See Sections 1.3.1 and 1.3.2
For those instruments, the information included in this addendum supersedes the information
related to the relay PCA that appears in the chapters on Theory of Operation and Troubleshooting
& Repair of your M100E/M200E/M400E operator’s manual’s.
Because the operator’s manual for each model family of the E-Series instruments is slightly
different there is no direct correspondence between the sections and chapters of this addendum
and those of the manual.
1.1. What’s the Same
In most respects the electronic operation of the Relay PCA 04523 is the same as Relay PCA
03955.
Both are used by the CPU to operate various AC and DC heaters that control the
temperature of key components of the E-Series analyzers to such as sensor modules,
reaction cells and converters as well as certain optional components such as IZS
permeation tubes.
In both cases a set of configuration jumpers located on the relay card is used to configure
the heaters for 110 VAC, 60 Hz vs. 230 VAC, 50 Hz operation.
Both Relay cards, based on commands from the CPU received over the I2C bus,
energize/de-energize the various solenoid valves used to control the sample gas path of
the analyzers (e.g. reference/measure valves; zero-span-cal valve options; IZS options;
etc.)
Both distribute the AC and DC power to the various electrically powered components and
assemblies for the instrument.
Both include a special watchdog circuit watches that will automatically shut of all valves as
well as turn off the UV Source(s) and all heaters should either the CPU cease issuing
commands or the I2C bus fail. In both cases the sample pump will continue to run.
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Relay PCA 04523
1.2. What’s Different
The major differences between the Relay PCA 04523 and Relay PCA 03955 are:
On instruments with internal pumps, the pump is now configured for use with 110 VAC, 60
Hz vs. 220 VAC, 50 Hz operation by a set of configuration jumpers on the Relay PCA.
Previously a set of inline connectors and wiring harnesses performed this function.
The configurability of the two thermocouple inputs has been expanded to allow for both
grounded and ungrounded thermocouples
A retainer plate has been added to the 045230200 version to keep the solid state AC
power relays securely inserted in their sockets.
Because the board has been physically changes, locations of components such as jumper
blocks, connectors and status LED’s have changed.
1.3. Relay PCA Location and Layout
Generally the relay PCA is located in the right-rear quadrant of the analyzer and is mounted
vertically on the back side of the same bracket as the instrument’s DC power supplies, however
the exact location of the relay PCA may differ from model to model. Please check the Getting
Started chapter of your M100E/M200E/M400E operator’s manual.
Status LED’s
(D2 through D16)
Thermocouple
Signal Output
Watchdog
Status LED (D1)
DC Power Supply
Test Points
(JP5)
Thermocouple
Configuration
Jumpers
I2C Connector
(J15)
TC1 Input
Power
Connection
for DC
(J16)
Heaters
TC2 Input
Shutter Control
(JP7)
Pump AC
Configuration
Jumper
Connector
(M100E Series
Only)
Valve Control
Drivers
Pump Power
Output
Valve Option
Control
Connector
AC Power
IN
AC Heater
Power Output
DC Power
Distribution
Connectors
Solid State AC
Power Relays
(Not Present on
P/N 45230100)
(JP6)
Main AC Heater
Configuration Jumpers
(JP2)
AC Configuration Jumpers
for Optional IZS Valve
Heaters & 02Sensors
AC Power Output for
Optional IZS Valve
Heaters & 02 sensors
Figure 1-1:
Relay PCA Layout (P/N04523)
2
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There are two versions of the new relay card. Table 1-1 above cross references the PCA version
with the various E-series analyzer models.
1.3.1. Version 045230200
This is the most commonly used version of the Relay PCA. It includes a bank of solid state AC
relays. This version is installed in analyzers where components such as AC powered heaters must
be turned ON & OFF. A retainer plate is installed over the relay to keep them securely seated in
their sockets.
Retainer
Mounting
Screws
AC Relay
Retainer Plate
Figure 1-2:
Relay PCA P/N 045230200 with AC Relay Retainer In Place
1.3.2. Version 045230100
This is the base version of the Relay PCA. It does not include the AC relays and is used in
instruments where there are no AC powered components requiring control. A plastic insulating
safety shield covers the empty AC Relay sockets (See Figure 1-3)
CAUTION
Never remove this safety shield while the instrument is plugged in and
turned on. The contacts of the AC relay sockets beneath the shield carry
high AC voltages even when no relays are present
AC Relay
Safety Shield
Figure 1-3:
Relay PCA P/N 045230100 with Safety Shield In Place
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Relay PCA 04523
USER NOTES:
4
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2. OPERATION AND CONFIGURATION
2.1. Power Distribution
SENSOR SUITES
KEY
AC POWER
DC POWER
Sensor Control
ANALOG
& I/O Logic
SENSORS
(e.g. UV sensors,
Temp Sensors,
Flow Sensors,
IR, Sensors,
LOGIC DEVICES
Pre-Amplifiers
& Amplifiers
(e.g. CPU, I2C bus,
Keyboard, Display,
MotherBoard, etc.)
PMT HVPS, etc.)
PS 1
+5 VDC
±15 VDC
Configuration
Jumpers
PUMP
ON / OFF
SWITCH
Configuration
Jumpers
AC HEATERS
AC HEATERS for
OPTIONAL IZS
Configuration
Jumpers
PERMEATION TUBE
AND O2 SENSOR
PS 2
(+12 VDC)
UV Lamp
P/S
Solenoid
Drivers
RELAY PCA
AC
POWER IN
MODEL SPECIFIC
COOLING
FAN(S)
OPTIONAL
VALVES
(e.g. Sample/Cal,
Zero/Spans, etc.)
UV SHUTTER
SOLENOID
(M100E Series Only)
VALVES
(e.g. M/R Valves,
Auto-zero valves,
etc.)
Figure 2-1:
Power Distribution Block Diagram
2.1.1. AC Power Configuration
The E-Series digital electronic systems will operate with any of the specified power regimes. As
long as instrument is connected to 100-120 VAC or 220-240 VAC at either 50 or 60 Hz it will turn
on and after about 30 seconds show a front panel display. Internally, the status LEDs located on
the Relay PCA, Motherboard and CPU should turn on as soon as the power is supplied.
On the other hand, some of the analyzer’s non-digital components, such as the pump and the
various AC powered heaters must be properly configured for the type of power being supplied to
the instrument. Figure 2-3 shows the location of the various sets of AC Configuration jumpers.
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Relay PCA 04523
JP6
IZS Permeation
Tube Heater and O2
Sensor Connection.
(optional)
JP2
Main AC Heater
Configuration
JP7
Pump
Configuration
Figure 2-2:
Location of AC power Configuration Jumpers
There are several changes between the Relay PCA 04523 and previous version regarding AC
power configuration and distribution.
Previously, in analyzer models with internal pumps, the AC power for the pump came
directly from the instrument back panel. The 04523 version handles all AC and DC power
distribution including power to the pump.
Prior to this change, configuring the pump for compatibility with various line voltages and
frequencies was done with a set of hard-wired, in-line connections. The Relay PCA
04523, now includes a set of jumpers that perform this function. This change increase
reliability and simplifies troubleshooting and repair operations.
The Relay PCA 04523, includes a set of jumpers that connect AC power to heaters
included in several optional items, such as the IZS valve option and the O2 sensor option
available on the M100E, M200E and M400E series instruments. In earlier versions of the
relay PCA this was also handled by in-line connections.
6
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2.1.1.1. AC configuration – Internal Pump (JP7)
AC power configuration for internal pumps is set using Jumper set JP7 (see Figure 1-1 for the
location of JP7).
Table 2-1:
AC Power Configuration for Internal Pumps (JP7)
JUMPER
BETWEEN
PINS
LINE
POWER
LINE
FREQUENCY
JUMPER
FUNCTION
COLOR
Connects pump pin 3 to 110 / 115 VAC power line
2 to 7
3 to 8
4 to 9
60 HZ
WHITE
BLACK
Connects pump pin 3 to 110 / 115 VAC power line
Connects pump pins 2 & 4 to Neutral
110VAC
115 VAC
Connects pump pin 3 to 110 / 115 VAC power line
Connects pump pin 3 to 110 / 115 VAC power line
Connects pump pins 2 & 4 to Neutral
2 to 7
3 to 8
4 to 9
50 HZ1
Connects pump pins 3 and 4 together
Connects pump pin 1 to 220 / 240VAC power line
Connects pump pins 3 and 4 together
1 to 6
3 to 8
1 to 6
3 to 8
60 HZ
BROWN
BLUE
220VAC
240 VAC
50 HZ1
Connects pump pin 1 to 220 / 240VAC power line
1
A jumper between pins 5 and 10 may be present on the jumper plug assembly, but is only functional on
the M300E and has no function on the Models M100E, M200E or M400E.
110 VAC /115 VAC
220 VAC /240 VAC
1
2
3
4
5
1
2
3
4
5
6
7
6
7
8
8
9
9
10
10
Present on 50 Hz version of jumper set,
and functional for M300E but not
Models M100E, M200E & M400E
Figure 2-3:
Pump AC Power Jumpers (JP7)
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Relay PCA 04523
2.1.1.2. AC Configuration – Standard Heaters (JP2)
Power configuration for the AC the standard heaters is set using Jumper set JP2 (see Figure 1-1
for the location of JP2).
Table 2-2:
Power Configuration for Standard AC Heaters (JP2)
JUMPER
BETWEEN
PINS
JUMPER
COLOR
MODEL’S
LINE VOLTAGE
HEATER(S)
FUNCTION
USED ON1
Common
1 to 8
Reaction Cell / Sample
Chamber Heaters
M100E’s &
M200E’s
Neutral to Load
Common
2 to 7
3 to 10
4 to 9
Mini Hi-Con
Converter
M200EH
110 VAC / 115 VAC
50Hz & 60 Hz
Neutral to Load
Common
WHITE
3 to 10
4 to 9
M101E and
M200E’s
Moly Converter
By Pas Manifold
Neutral to Load
Common
5 to 12
6 to 11
M200#M &
M200EH
Neutral to Load
Reaction Cell / Sample
Chamber Heaters2
M100E’s &
M200E’s
Load
1 to 7
3 to 9
3 to 9
5 to 11
Hi Concentration
Converter
M100EH
Load
Load
Load
220 VAC / 240 VAC
50Hz & 60 Hz
BLUE
M101E and
M200E’s
Moly Converter
By Pas Manifold
M200#M &
M200EH
1
No AC Heaters are used in the M400E series analyzers.
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
Reaction Cell or
Sample Chamber
Heaters
Reaction Cell or
Sample Chamber
Heaters
8
9
9
Mini Hi-Con or
Moly Converter
Heaters
Mini Hi-Con or
Moly Converter
Heaters
10
10
11
12
11
12
200EM/EH
By Pass Manifold
Heater
200EM/EH
By Pass Manifold
Heater
220 VAC / 240 VAC
110 VAC /115 VAC
Figure 2-4:
Typical Set Up of AC Heater Jumper Set (JP2)
8
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2.1.1.3. AC Configuration –Heaters for Option Packages (JP6)
Both the IZS valve option or an O2 sensor options include AC heaters that maintain an optimum
operating temperature for key components of those options. Jumper set JP6 is used to connect
the heaters associated with those options to AC power. Since these heaters work with either
110/155 VAC or 220/240 VAC, there is only one jumper configuration.
Table 2-3:
Power Configuration for Optional AC Heaters (JP6)
JUMPER
BETWEEN
PINS
JUMPER
COLOR
MODEL’S
HEATER(S)
FUNCTION
USED ON1
M100E’s,
M200E’s &
M400E
Common
1 to 8
IZS Permeation Tube
Heater
Neutral to Load
Common
2 to 7
3 to 10
4 to 9
RED
M100E’s &
M200E’s
O2 Sensor Heater
Neutral to Load
10
9
IZS
Permeation Tube
12
11
8
2
7
1
O2 Sensor
Heater
Heater
6
5
4
3
Figure 2-5:
Typical Set Up of AC Heater Jumper Set (JP2)
2.2. Valve Control
Other than the location of the connectors and control chips on the PCA (see Figure 1-1 above),
there have been no significant changes to the method by which the E-Series instruments’ various
valves and valve options are controlled.
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Relay PCA 04523
2.3. Status LEDs & Watch Dog Circuitry
Like the previous version, the status LED’s on the Relay PCA 04523 includes thirteen LEDs that
indicate the status of the analyzer’s heaters, valves and other general operating conditions. Since
the functions represented by these LED differs from model to model, check your
M100E/M200E/M400E operator’s manual for their exact assignments (this can normally be found
in the section on Electronic Theory of Operation).
While the functional assignments for the LED’s of each model have remained unchanged their
location on the PCA is different. See Figure 2-3 of this addendum for the new locations.
2.3.1. Watchdog Indicator (D1)
The most important of the status LED’s on the relay board is the red I1C Bus watch-dog LED. It is
controlled directly analyzer’s CPU over the I2C bus. Special circuitry on the relay PCA watches the
status of D1. Should this LED ever stay ON or OFF for 30 seconds, indicating that the CPU or I2C
bus has stopped functioning, this Watchdog Circuit automatically shuts all valves and turn off all
heaters and lamps.
D7 (Green)
D8 (Green)
D9 (Green)
D4 (Yellow)
D3 (Yellow)
D2 (Yellow)
D10 (Green)
D5(Yellow)
D6 (Yellow)
D11 (Green)
D12 (Green)
D13 (Green)
D14 (Green)
D15 (Green)
D16 (Green)
D1 (RED)
Watchdog
Indicator
Figure 2-6:
Status LED Locations – Relay PCA 04523
10
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2.4. Heater Control Loop
Thermistor(s) – Low Temperature Sensing:
(e.g. Sample Chamber and Reaction
Cell temperatures)
MOTHER BOARD
A/D
Converter
(V/F)
RELAY PCA
Preamplifiers
and Signal
Conditioning
CPU
THERMOCOUPLE
CONFIGURATION
JUMPER
Cold Junction
Compensation
(JP5)
DC
Themocouple(s)
(High Temperature Sensing;
e.g. Moly and HiCon
Control
Logic
Solid State
AC Relays
Converter temperatures)
DC HEATERS
AC HEATERS
Figure 2-7:
Heater Control Loop Block Diagram.
While the role of the heater control lop for the E-Series analyzers is basically unchanged from the
previous version (see Figure 2-4) the configurability of the Thermocouple inputs has been
enhanced. Previously, the two T/C inputs could be configured for either type-T or type-K
thermocouples. The 04523 relay PCA adds the following.
Both T/C’s can now be configured as either grounded or ungrounded thermocouples.
Standard configuration of the both type of thermocouples is 10 mV/°C. In order to
accommodate the M200EH’s Mini High-Con converter option, a type-K; 5mV/°C output
configuration has been added.
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Relay PCA 04523
2.4.1. Thermocouple Inputs and Configuration Jumper (JP5)
Although the 04523 relay PCA supports two thermocouple inputs, the current M100E/M200E
series analyzers only utilize one and the M400E series analyzers none. By default, this single
thermocouple input is plugged into the TC1 input (J15). TC2 (J16) is currently not used. See
Figure 1-1 for location of J15 and J16
Table 2-4:
Thermocouple Configuration Jumper (JP5) Pin-Outs
TC INPUT
JUMPER PAIR
DESCRIPTION
FUNCTION
Selects preamp gain factor for J or K TC
- IN = J TC gain factor
Gain Selector
1 – 11
- OUT = K TC gain factor
Selects preamp gain factor for J or K TC
- IN = 5 mV / °C
Output Scale Selector
2 – 12
- OUT = 10 mV / °C
When present, sets Cold Junction
Compensation for J type Thermocouple
3 – 13
4 – 14
Type J Compensation
Type K Compensation
TC1
When present, sets Cold Junction
Compensation for K type Thermocouple
Selects between Isolated and grounded
TC
5 – 15
Termination Selector
- IN = Isolate TC
- OUT = Grounded TC
Gain Selector
Same as Pins 1 – 11 above.
Same as Pins 2 – 12 above.
Same as Pins 3 – 13 above.
Same as Pins 4 – 14 above.
Same as Pins 5 – 15 above.
6 – 16
7 – 17
8 – 18
9 – 19
10 – 20
Output Scale Selector
Type J Compensation
Type K Compensation
Termination Selector
TC2
12
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TC1
TC2
Figure 2-8:
Thermocouple Configuration Jumper (JP5) Pin-Outs
Table 2-5:
Typical Thermocouple Settings for M100E/M200E series analyzers
OUTPUT
SCALE
TYPE
JUMPER
BETWEE
N PINS
TC
TYPE
TERMINATION
TYPE
JUMPER
COLOR
USED ON
INPUT TC1 (J15)
2 – 12
4 – 14
GROUNDED
5mV / °C
5mV / °C
10mV / °C
10mV / °C
10mV / °C
M100EH with Mini HiCon Converter BROWN
K
2 – 12
4 – 14
5 – 15
ISOLATED
M100EH with Mini HiCon Converter
GREY
K
4 – 14
5 – 15
ISOLATED
M100E/M200E with Moly Converter PURPLE
K
1 – 11
3 – 13
5 – 15
ISOLATED
M100E/M200E with Moly Converter
M100E/M200E with Moly Converter
RED
J
1 – 11
3 – 13
GROUNDED
GREEN
J
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2.5. DC Power Supply Test Points
The tables defining the names and functions of the DC power test point that appear in Chapter 11
of some revisions of the M100E/M200E/M400E operator’s manual are incorrect. The following
tables show the correct information.
Table 2-5:
DC Power Test Point and Wiring Color Code
NAME
DGND
+5V
TEST POINT#
COLOR
Black
DEFINITION
Digital ground
1
2
3
4
5
6
7
Red
AGND
+15V
-15V
Green
Blue
Analog ground
Yellow
Purple
Orange
+12R
+12V
12 V return (ground) line
Table 2-6:
DC Power Supply Acceptable Levels
CHECK RELAY BOARD TEST
POINTS
POWER VOLTAG
MIN V
MAX V
FROM
TO
Test Point
SUPPLY
E
Test Point
NAME
#
NAME
#
PS1
PS1
PS1
PS1
PS1
PS2
PS2
+5
+15
DGND
AGND
1
3
3
3
1
6
6
+5
+15
2
4
5
1
+4.80
+13.5
-14.0
-0.05
-0.05
+11.8
-0.05
+5.25
+16.0
-16.0
-15
AGND
-15V
DGND
AGND
Chassis
+12
AGND
+0.05
+0.05
+12.5
+0.05
DGND
Chassis
+12V
N/A
7
+12V Ret
+12V Ret
DGND
DGND
1
As on the previous version of the relay card, the test points are located at the top, right-hand
corner of the PCA (see Figure 1-1)
USER NOTES:
14
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3. TROUBLE SHOOTING AND REPAIR
General Trouble shooting hints for the relay PCA are the same as described for the previous
versions for the PCA. See Chapter 11 of your M100E/M200E/M400E operator’s manual for more
information.
3.1. Removing / Replacing the Relay PCA from the
Instrument
The Relay retainer plate installed on the 045230200 PCA (version with AC relays) covers the lower
right mounting screw of the relay PCA. Therefore, when removing the relay PCA, the retainer
plate must be removed first.
Mounting
Screws
AC Relay Retain Occludes
Mounting Screw on
P/N 045230200
Figure 3-1:
Relay PCA 04523 Mounting Screw Locations
USER NOTES:
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Addendum to E-Series Operator Manuals
Relay PCA 04523
4. SCHEMATICS AND SPARE PARTS FOR RELAY
PCA P/N 04523
Table 4-1:
List of Spare Parts
DOCUMENT TITLE
DOCUMENT #
RL0000015
Relay, DPDT, AC, Solid State, E-Series
Module, Relay PCA & Power Supply
041520500
Table 4-2:
List of Included Electronic Schematics
DOCUMENT #
DOCUMENT TITLE
04524
PCA, 04523, M100E, M200E, M400E Relay PCB
USER NOTES:
16
05118 Rev B3
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